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IDEAL LOGIC Combi ES Series Installation And Servicing
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IDEAL LOGIC Combi ES Series Installation And Servicing

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INSTALLATION
AND SERVICING
LOGIC Combi ES
ES24, ES30, ES35
For users guide see reverse of book
For details of document amendments, refer to page 3
When replacing any part on this appliance, use only spare parts that you can be
assured conform to the safety and performance specification that we require.
Do not use reconditioned or copy parts that have not been clearly authorised by Ideal.
For the very latest copy of literature for specification and maintenance practices visit our
website www.idealboilers.com where you can download the relevant information in PDF format.
January 2014
UIN 208383 A02

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Summary of Contents for IDEAL LOGIC Combi ES Series

  • Page 1 Do not use reconditioned or copy parts that have not been clearly authorised by Ideal. For the very latest copy of literature for specification and maintenance practices visit our website www.idealboilers.com where you can download the relevant information in PDF format.
  • Page 2 Logic Combi ES - Installation and Servicing...
  • Page 3 New pages added, Flowchart for CO Level and Combustion Ratio Check on Commissioning a Condensing Boiler UsER gUIDE page 3 Addition of Weather Compensation paragraph Ideal Stelrad Group reserve the right to vary specification without notice Logic Combi ES - Installation and Servicing...
  • Page 4 general Table 1 - general Data Logic Combi Es Es24 Es30 Es35 Gas supply 2H - G20 - 20mbar Gas Supply Connection 15mm copper compression Injector Size (mm) 4.15 4.65 Inlet Connection Domestic Hot Water 15mm copper compression Outlet Connection Domestic Hot Water 15mm copper compression Flow Connection...
  • Page 5 general CONTENTs Logic Combi ES Natural gas only air supply ..............9 Boiler size g.C. appliance No. pI No. Benchmark Commissioning Checklist ..... 60 (Benchmark No.) Boiler Clearances ............10 Boiler Exploded Diagram ........... 13 ES24 47-349-01 86 CL 08 Condensate Drain ........
  • Page 6 general INTRODUCTION OpERaTION The Logic Combi Es range of boilers are wall mounted, full With no demand for CH, the boiler fires only when DHW is drawn sequence, automatic spark ignition, low water content, fanned off. flue, high efficiency, condensing, combination gas boilers. When there is a demand for CH, the heating system is supplied Note.
  • Page 7 Installation and Servicing Instructions or as otherwise • RF Electronic Programmable Room Thermostat (7 day) recommended by Ideal stelrad group in writing. If in doubt please enquire. Any direct connection of a control device not approved by Ideal stelrad group could invalidate the certification and the normal appliance warranty.
  • Page 8 general gas sUppLy LOCaTION OF BOILER The local gas supplier should be consulted, at the installation The boiler must be installed on a flat and vertical internal wall, planning stage, in order to establish the availability of an adequate capable of adequately supporting the weight of the boiler and any supply of gas.
  • Page 9 general TERMINaL 2. It is important that the position of the terminal allows the free passage of air across it at all times. The terminal assembly can be adapted to accommodate various 3. Minimum acceptable spacing from the terminal to obstructions wall thicknesses.
  • Page 10 general BOILER DIMENsIONs, sERVICEs & CLEaRaNCEs all dimensions in mm The boiler connections are made on the boiler connection tails. Refer to Frame 24. wall thicknesses do not exceed 600mm (24”). Where the The following minimum clearances must be maintained for space into which the boiler is going to be installed is less operation and servicing.
  • Page 11 general sysTEM REqUIREMENTs - Central heating safety valve setting Notes Vessel charge pressure 0.5 to 0.75 a. The method of filling, refilling, topping up or flushing sealed primary hot water circuits from the mains via a temporary hose system pre-charge pressure bar None connection is only allowed if acceptable to the local water system volume...
  • Page 12 The application of any other treatment to this product softened water, however, is not permitted. may render the guarantee of Ideal stelrad group Ideal stelrad group recommend the use of Fernox Quantomat, Invalid. Sentinel Combiguard,Calmag CalPhos I scale reducing devices...
  • Page 13 INSTALLATION BOILER assEMBLy - Exploded View Note that item numbers are linked to the spares list CH Return Valve Return Group Manifold Burner Electrode Ignition CH Flow Valve Flow Group Manifold Gasket - Burner Electrode Detection DHW Inlet & Outlet Plate Heat Exchanger Sump Clean Out Cover Ignitor Unit...
  • Page 14 INSTALLATION UNpaCKINg The boiler is supplied fully assembled in Pack A. A telescopic or non-telescopic flue assembly for rear or side flue outlet in Pack B is suppled as a separate order. Unpack and check the contents. pack a Contents Boiler Hardware Pack Box Wall Mounting Plate...
  • Page 15 INSTALLATION UNpaCKINg CONT’D Note. This flue system incorporates a removable flue outlet nose that utilises a push fit location system. This enables the installation of deflector, high level or balcony outlet flue kits without the removal of the whole ‘B’ pack terminal. The appliance must not be operated without the desired outlet nose correctly fitted in place.
  • Page 16 INSTALLATION 10 WaLL MOUNTINg TEMpLaTE Extended centre line 1 5 5 (2 0 0 ) The wall mounting template is located on the internal protective “A” - See Diagram in Frame 1 packaging. The template shows the position of the fixing and rear flue centre holes for a standard installation Care MUST be taken to ensure the correct holes are drilled.
  • Page 17 INSTALLATION 14 DETERMININg ThE FLUE LENgTh aND FLUE paCKs REqUIRED IMPORTANT. The boiler must be installed in a vertical position in accordance to the installation instructions. FLUE KITs Telescopic Flue‘B’ pack - contains: Flue turret, telescopic flue incorporating a terminal and rubber wall seals. horizontal Flue Terminal (600mm long) ‘B’...
  • Page 18 INSTALLATION 15 DETERMININg ThE FLUE LENgTh aND FLUE paCKs REqUIRED, CONT’D FIgURE 1 Edge of turret Edge of turret Edge of turret to outside face of wall plus to outside face of wall plus to outside face of wall plus 44mm = ue length 44mm = ue length 44mm = ue length...
  • Page 19 INSTALLATION 16 CUTTINg & sETTINg ThE FLUE LENgTh TELEsCOpIC FLUEs TELEsCOpIC FLUE B paCK SHOULD ONLY BE ADJUSTED FOR USE WITHIN ITS SPECIFIED RANGE AND MUST NOT BE CUT hORIzONTaL FLUE TERMINaL (1000MM LONg) B paCK (TELEsCOpIC) MUST ONLY BE CUT IF REQUIRED FLUE LENGTHS ARE BETWEEN 602 &...
  • Page 20 INSTALLATION 17 INsTaLLINg ThE FLUE FITTINg FLUE ThROUgh ThE WaLL 1. Measure wall thickness and add 14mm. 2. Measure from the outer terminal lip towards the end of outer flue, place a small location mark at the dimension acquired at point 1. 3.
  • Page 21 INSTALLATION 18 FITTINg ThE OpTIONaL ROOF FLUE KIT (Flat or pitched) Note. A flat or pitched roof flashing plate (not supplied) is required before proceeding with the installation of this kit. This kit is suitable for both flat and pitched roof terminations, using a concentric flue to run vertically from the top of the boiler and terminating above roof level.
  • Page 22 INSTALLATION 20 FLUE TERMINaL pOsITION The terminal should be positioned so that products of combustion can safely disperse at all times. pluming may occur at the termination so, where possible, terminal positions where this could cause a nuisance should be avoided. Minimum dimensions are shown below 300mm 625mm...
  • Page 23 INSTALLATION 21 assEMBLINg ThE ROOF FLUE KIT Determine the correct height that the flue should terminate above the roof. If after calculating or measuring the overall flue height from the top of the boiler, it is necessary to cut both pipes of assembly A, then ensure they are cut equally leaving the inner flue tube longer than the outer air tube as supplied.
  • Page 24 INSTALLATION 22 CONDENsaTE DRaIN Condensate pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point, a condensate pump of a specification recommended by the boiler or pump manufacturer should be used terminating into a suitable internal foul water discharge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc.
  • Page 25 INSTALLATION 23 CONDENsaTE DRaIN - CONT’D..Figure 3 - Connection of a Condensate Pump Typical Figure 4 - Connection of condensate Drainage Pipe to Method (see manufacturers detailed instructions) External Soil & Vent Stack Boiler Water/weather Visible air break with 75mm proof insulation Boiler sealed...
  • Page 26 INSTALLATION 24 CONNECTIONs & FILLINg NOTEs. Note. The domestic hot water flow rate is Ensure all boss blanking plugs are removed before connecting hardware. Each automatically regulated to a maximum: valve must be fitted to the correct boss as shown in the picture. E24 = 9.9 (2.2 gpm) Ensure each union is fitted with fibre seals provided.
  • Page 27 6. Swing the control box back up into the operating condition and re-fit the front panel ensuring a good seal is made. Ideal offer 4 kits as follows: ROOM ThERMOsTaT (NO TIMER) - WIRINg (see individual kits for installation instructions) 1.
  • Page 28 INSTALLATION 27 INTERNaL WIRINg DIAGRAM B DIAGRAM A Room External Internal Timer or Room Stat or Timer Stat Programmable Room Stat Prog. Room Stat ROOM ROOM STAT/ STAT/ TIMER TIMER Optional Optional Frost Stat Frost Stat FROST FROST STAT STAT OPTIONAL OPTIONAL Separate Timer and Room Stat...
  • Page 29 INSTALLATION 30 WIRINg DIagRaM Logic Combi ES - Installation and Servicing...
  • Page 30 INSTALLATION 31 COMMIssIONINg aND TEsTINg a. Electrical Installation B. gas Installation 1. Checks to ensure electrical safety should be carried out by a 1. The whole of the gas installation, including the meter, competent person. should be inspected and tested for tightness and purged in accordance with the recommendations of BS.
  • Page 31 INSTALLATION 32 INITIaL LIghTINg Legend a. Blank B. DHW temperature control C. CH temperature control D. Off/Summer/Winter/Reset Control E. Boiler Status F. Burner ‘on’ indicator g. CH Flow Isolating Valve h. Pressure Gauge J. Gas Inlet Pressure Test Point K. Gas Service Cock L.
  • Page 32 INsTaLLaTION 33 gENERaL ChECKs Make the following checks for correct operation in: DOMEsTIC hOT WaTER (DhW) MODE WaTER CIRCULaTION sysTEM 1. Fully open all DHW taps in turn and ensure that water flows 1. With the system COLD, check that the initial pressure is freely from them.
  • Page 33 INSTALLATION 34 REsET pROCEDURE To reset boiler, turn the mode control knob (D) to reset position and immediately turn knob back to required setting. The boiler will repeat the ignition sequence if a heat demand is present. Legend a. Blank D.
  • Page 34 (and gas rate) have been verified, then contact Ideal. 11. Complete the service section in the Benchmark Commissioning Checklist. Logic Combi ES -...
  • Page 35 SERVICING 37 BOILER FRONT paNEL REMOVaL / REpLaCEMENT REMOVaL 1. Loosen the two screws retaining the front panel. 2. Pull the two spring clips down to disengage and pull panel forward and upward and remove. REpLaCEMENT 3. Hook the panel onto the top retaining clips. 4.
  • Page 36 SERVICING 39 BURNER REMOVaL aND CLEaNINg 1. Ensure the sump is fully drained 2. Undo the two screws and remove the sump cover retaining the lower flue manifold. 3. Lift the manifold to clear the bottom sealing gasket and remove manifold.
  • Page 37 SERVICING 41 CLEaNINg ThE hEaT ExChaNgER note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to Ignition Electrode Flame Detection Frame 59. 1. Remove ignition and flame detection electrodes. Refer to Frames 48 & 49. 2. It is advisable to replace the sump cover prior to the water flush process.
  • Page 38 SERVICING 43 REpLaCEMENT OF COMpONENTs gENERaL After replacing ANY component check operation of the boiler, including gas soundness, gas rate and combustion When replacing aNy component test. 1. Isolate the electricity supply. IMpORTaNT. When work is complete, the front panel must be correctly 2.
  • Page 39 SERVICING 45 BURNER INJECTOR REpLaCEMENT 1. Refer to Frame 43. 2. Disconnect the electrical leads from the fan. 3. Undo the gas pipe union connection to the injector housing. 4. Loosen the screw retaining the fan mounting bracket. 5. Lift and remove the fan and venturi assembly. 6.
  • Page 40 SERVICING 47 RETURN ThERMIsTOR RENEWaL 1. Refer to Frame 43. 2. Unclip the return thermistor from the return pipe and withdraw it from the boiler. 3. Disconnect the electrical lead from the thermistor. 4. Reconnect the electrical lead to the new thermistor and reassemble in reverse order, ensuring that the thermistor is securely fitted to the pipe on the thermistor locator tab as shown.
  • Page 41 SERVICING 49 FLaME DETECTION ELECTRODE REpLaCEMENT 1. Refer to Frame 43. Flame Detection Electrode 2. Remove the burner. Refer to Frame 46. 3. Unplug the flame detection lead from the electrode. 4. Remove the 2 screws retaining the detection electrode. 5.
  • Page 42 SERVICING 52 DIVERTER VaLVE aCTUaTOR REpLaCEMENT 1. Refer to Frame 43. 2. Remove the electrical plug. 3. Using a suitable tool pull out the retaining clip and lift the diverter head from the brass body. 4. Fit new actuator head and reassemble in reverse order.
  • Page 43 SERVICING 54 MaIN pCB REpLaCEMENT Note that production boiler PCBs are factory pre-set to operate for boiler range and output, but when ordering Primary PCB as a spare, an additional Boiler Chip Card Note. Fit the earth strap provided with the PCB to (BCC) MUST also be purchased for your specific boiler range and output.
  • Page 44 SERVICING 56 DhW FLOW TURBINE sENsOR REpLaCEMENT 1. Refer to Frame 43. 2. Remove condensate trap/siphon. Refer to Frame 53. 3. Lift off the flow turbine sensor plastic retaining clip. 4. Unplug the electrical connection and transfer to new turbine sensor. 5.
  • Page 45 SERVICING 59 saFETy RELIEF VaLVE RENEWaL 1. Refer to Frame 43. 2. Drain the boiler. Refer to Frame 57. 3. Remove the condensate trap/siphon. Refer to Frame 53. 4. Remove expansion vessel. Refer to Frame 69. 5. Disconnect the electrical connection from the return thermistor.
  • Page 46 SERVICING 62 DIVERTER VaLVE INTERNaL CaRTRIDgE REpLaCEMENT FRONT CaRTRIDgE REpLaCEMENT REaR CaRTRIDgE REpLaCEMENT 1. Refer to Frame 43. 1. Refer to Frame 43. 2. Drain the boiler. Refer to Frame 57. 2. Drain the boiler. Refer to Frame 57. 3. Remove the diverter valve head. Refer 3.
  • Page 47 SERVICING 65 Ch WaTER pREssURE sENsOR REpLaCEMENT 1. Refer to Frame 43. 2. Drain the boiler. Refer to Frame 57. 3. Remove condensate trap/siphon. Refer to Frame 53. 4. Using a suitable tool pull out the retaining clip. 5. Pull the pressure sensor upwards to remove. 6.
  • Page 48 SERVICING 68 hEaT ENgINE RENEWaL Refer also to Frame 6 - ‘Boiler Exploded View’ IMpORTaNT Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag. 1. Refer to Frame 43. 11. Undo the inlet pipe union nut and remove the retaining spring clip and remove pipe.
  • Page 49 SERVICING 69 ExpaNsION VEssEL REChaRgINg & REpLaCEMENT Recharge REChaRgINg Point 1. Refer to Frame 43. 2. Remove the charge point cover. 3. Recharge the tank pressure to 0.75 bar. 4. Re-assemble in reverse order 5. Check operation of the boiler. Refer to Frames 32 &...
  • Page 50 Fault Finding 71 FaULT FINDINg ChaRT MaIN MENU gO TO FRaME 72 - aLTERNaTINg ‘L’ and ‘1’ FLOW TEMpERaTURE OVERhEaT LOCKOUT gO TO FRaME 73 - aLTERNaTINg ‘L’ and ‘2’ IgNITION LOCKOUT 5 REsETs WIThIN 15 MINs - aLTERNaTINg ‘L’ and ‘5’ TURN pOWER OFF aND ON gO TO FRaME 74 - aLTERNaTINg ‘L’...
  • Page 51 Fault Finding 72 aLTERNaTINg ‘L’ aND ‘1’ - FLOW TEMpERaTURE OVERhEaT LOCKOUT Is the Boiler and CH System filled with water and all Fill and vent the system and open all isolation and radiator valves open? isolation valves, then reset boiler Is the Flow/Return Differential across the Boiler in Check that the Pump is rotating freely.
  • Page 52 Fault Finding 74 aLTERNaTINg ‘L’ aND ‘6’ - FaLsE FLaME LOCKOUT Check routing and integrity of internal boiler Reset the boiler, does Boiler Work OK? wiring is OK. Check condition of Flame Sense Electrode and replace if deteriorated. Replace Flame Detection Electrode Separate the flame detection electrode in-line connector.
  • Page 53 Fault Finding 77 aLTERNaTINg ‘F’ aND ‘3’ - FaN FaULT Does the wiring from the Fan to the PCB have Rectify Wiring & secure connections at both ends and has not connections deteriorated? Does the wiring have continuity? Replace PCB Is there 230Vac at the Blue and Brown connections to the 3 way connection on the Fan? Replace Fan...
  • Page 54 Fault Finding 80 aLTERNaTINg ‘F’ aND ‘6’ - OUTsIDE sENsOR FaULT Securely connect the wiring at both the Is the wiring securely connected at both the boiler and boiler and Outside Sensor Outside Sensor? Disconnect the wires to the outside sensor. Check the resistance using a suitable multimeter connected across the Outside Sensor’s terminal pins.
  • Page 55 Fault Finding 82 NO Ch OpERaTION BUT hW WORKs OK Move the mode knob to the Winter position Is the mode knob in the Winter position? Are the Timer and the Room Thermostat switched Switch the Timer and Room Thermostat On Open the Radiator Valves Are the Radiator Valves Open? There is no Voltage from the Timer/Room Stat.
  • Page 56 Fault Finding 83 NO hW BUT Ch ON YES Is hot and cold Is the red neon Does the display show “d” when a tap is on? illuminated on the turbine pipework crossed? sensor? Adjust flow rates to achieve 35º Are the flow rates correct as per Frame 2.
  • Page 57 When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal. Failure to do so could affect safety or performance of this appliance.
  • Page 59 Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the manufacturers instructions and the data fields on the commissioning checklist completed in full. To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation.
  • Page 60 GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Programmable room thermostat Optimum start control...
  • Page 61 SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 ² % ² % ² % ² % (Where Possible) (Where Possible) Signature Signature SERVICE 03 SERVICE 04...
  • Page 62 FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO CHECK ON COMMISSIONING A CONDENSING BOILER Important Preliminary Information on Checks The air gas ratio valve is factory-set and must not be adjusted DURING COMMISSIONING. If the boiler requires conversion to operate with a different gas family (e.g. conversion from natural gas to LPG) sepa- rate guidance is provided with the conversion kit supplied and this must be followed.
  • Page 63 0.2%? sampling point. Allow readings to stabilise before recording. Turn off appliance and call Ideal Technical Helpline for advice The appliance must not be commissioned until problems are identified CO level less and resolved. If commissioning cannot be fully completed, the appliance than 350ppm AND CO/CO must be disconnected from the gas supply in accordance with GSIUR.
  • Page 64 & servicing of central heating systems FM 59915 Ideal, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137. Ideal stelrad group pursues a policy of continuing improvement in the design and performance of its products.
  • Page 65 When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal.
  • Page 66 Benchmark Commissioning Checklist. You can check your installer by calling Gas Safe Register direct on 0800 4085500. Ideal stelrad group is a member of the Benchmark scheme and fully supports the aims of the programme. Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.
  • Page 67 Weather Compensation operation Winter conditions - i.e. Ch and DhW required. When the Weather Compensation option is fitted to the system then the CH Temperature Control (C) becomes a method of Ensure the mode knob control (D) is set to winter ( controlling room temperature.
  • Page 68 Loss of system water pressure Condensate Drain The gauge (G) indicates the central heating system pressure. This appliance is fitted with a siphonic condensate trap If the pressure is seen to fall below the original installation system that reduces the risk of the appliance condensate pressure of 1-2 bar over a period of time then a water leak may from freezing.
  • Page 69 See boiler “Operation Modes” section. If ‘0’ is displayed then provide central heating? and “Fault Codes” section contact Ideal Customer Services Helpline if your appliance is under warranty or a Gas Safe Check the time settings on the Registered Engineer, in IE a...
  • Page 70 OpERaTION MODEs DEsCRIpTION DIspLay CODE ON BOILER The boiler is in standby mode awaiting either a central heating call or hot water demand. The boiler has a call for central heating but the appliance has reached the desired temperature set on the boiler. The boiler has a call for hot water but the appliance has reached the desired temperature set on the boiler.
  • Page 71 5 Boiler Resets in 15 minutes 1. Turn power off and on at the fused spur. 2. If the boiler fails to operate please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period.
  • Page 72 Ideal Consumer Helpline Ideal stelrad group pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice. Tel: 01482 498660 Ideal, P.O. Box 103, National Ave, Kingston Upon Hull, HU5 4JN.

This manual is also suitable for:

Logic combi es24, logic combi es30, logic combi es35